SATO Elektronik

05.01

Satronik LS

Operating Instructions
Flame-cutting Machine

CE
EN50199

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Parking space for 2 cars Parking space for 2 cars Fig. DS-1
Table heights over 650 are implemented by means of a special under-structure in the
longitudinal track.
Nominal width (A) 2000mm-6000mm
Working width (B) Nominal width + 100mm
Table height (C) Standard table height
About 650mm

Nominal length (D) From 2500mm onwards, increasing by

Working length (E) Nominal2000mm
length + 100mm
Track length (F) Nominal length+ 1500mm

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Table of Contents

1 Guarantee .............................................................................................................................. 4
2 Address of the Manufacturer .................................................................................................. 5
3 Safety Instructions ................................................................................................................. 6
3.1 Introduction...................................................................................................................... 6
3.1.1 Protecting the Skin and Eyes .................................................................................... 6
3.1.2 Preventing fire ........................................................................................................... 7
3.1.3 Preventing electrical shocks ...................................................................................... 7
3.1.4 Preventing explosions ............................................................................................... 8
3.1.5 Pressure reducer....................................................................................................... 8
3.1.6 Gas supply from cylinders ......................................................................................... 8
3.1.7 Gas tubes ................................................................................................................. 8
3.1.8 Noise protection ........................................................................................................ 9
3.1.9 Safety devices........................................................................................................... 9
3.1.10 Specifications and Guidelines ................................................................................... 9
4 Specifications......................................................................................................................... 9
4.1 Description .....................................................................................................................10
4.1.1 General ....................................................................................................................10
4.1.2 CNC track control .....................................................................................................10
4.1.3 Burner height adjustment .........................................................................................10
4.1.4 Standard autogenous equipment .............................................................................10
4.1.5 Plasma Interlock Switch for one plasma flow source (optionally, several) ................11
4.2 Technical data ................................................................................................................11
4.2.1 Gantry bridge ...........................................................................................................11
4.2.2 Continuous path control CNC 8xx ............................................................................12
Continuous path control CNC 3xxx .......................................................................................12
5 Workplace .............................................................................................................................12
5.1 Safety area .....................................................................................................................14
6 Installation.............................................................................................................................15
6.1 Pre-installation ................................................................................................................15
6.1.1 On receiving the machine.........................................................................................15
6.1.2 Gas specifications ....................................................................................................15
6.1.3 Electrical power requirements ..................................................................................16
6.1.4 Potential equalization ...............................................................................................16
6.1.5 Connecting the power cable .....................................................................................16
6.2 Installation ......................................................................................................................16
6.2.1 Erection of the machine and its components ............................................................16
6.3 The correct foundation ....................................................................................................18
6.4 After installation ..............................................................................................................18
6.4.1 Starting the machine ................................................................................................18
6.4.2 General function test ................................................................................................18

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1 Guarantee

CAUTION !

The manufacturer specifies that original spare parts should be used for wearing parts. Any
damage that is caused as a result of non-usage of original SATO spare parts is excluded from
the guarantee.

For shortcomings in our shipments and services, we accept liability in accordance with our
"General Conditions of Business". Any additional claims are excluded.

The guarantee period is 12 months after commissioning, but not more than 13 months after
shipment, if the shipment or commissioning gets delayed for reasons beyond the control of Sato.

We do not undertake any guarantee for improper usage, inadequate maintenance or violent
damage.
Moreover, a guarantee claim is only valid provided that original spare parts and wearing parts
from SATO have been used. Wearing parts such as burners, nozzles, coaxial cables, sensing
shoes at the capacitive high sensing and similar parts are excluded from the guarantee.
Furthermore, all autogenous parts are excluded from the guarantee, because of the possibility of
a flashback.

The guarantee becomes null and void if, after commissioning by SATO, the user of the machine
or a third party installs a plasma source or another additional tool or device on the machine.

EXCEPT FOR THE GUARANTEES SPECIFIED HEREIN, SATO DOES NOT UNDERTAKE
ANY EXPRESS OR IMPLIED WARRANTEES FOR PRODUCTS THAT HAVE BEEN
MANUFACTURED BY SATO OR OTHER MANUFACTURERS. DEALERS ARE NOT
AUTHORIZED TO GIVE ANY OTHER GUARANTEES WHICH, UPON SALE OF THE
PRODUCTS TO THEIR CUSTOMERS, WOULD BE BINDING ON SATO.

Under no circumstances does SATO accept any liability for any accidental or indirect damage
such as damage to property, which may be due to faults in the machine sold herewith.

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2 Address of the Manufacturer

SATO Schneidsysteme

Böttgerstrasse 8
D - 41066 Mönchengladbach

Tel.: 0049 (0)2161 9942-0

Fax.: 0049 (0)2161 9942-14

E-mail: Sato@Sato.de

http//www.Sato.de

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3 Safety Instructions

3.1 Introduction

Any employee entrusted with the operation, maintenance or monitoring of the machine should
carefully read and understand the following safety regulations.

Warning!

A warning describes possible health hazards for the operating personnel and provides
instructions for preventing them.

Caution!

A caution describes a situation that can result in faults in the machine and provides information
on how to avoid or rectify the situation.

3.1.1 Protecting the Skin and Eyes

The safety glasses with side protection must be worn, in accordance with the national or regional
regulations for protecting the eyes from spray of slag or ultraviolet or infrared rays of the plasma
arc.
Damaged or broken glasses of the protective eyewear must be replaced immediately.
Persons in the immediate vicinity should be warned if they are not wearing any eye protection.

Protective clothing should be worn for protection from UV-radiation, flying sparks and hot metal.
- Handgloves, safety shoes and headwear must also be worn.
- Wear clothing that is fire-resistant and that covers you completely.
- Wear trousers without turn-ups, so that no sparks or slag can collect in the working clothes.
"Danger of fire"

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3.1.2 Preventing fire

Flame-cutting with this machine generates hot metal and hot slag. The following measures
should be taken to prevent fire.

• There should be fire extinguishers available in the immediate vicinity of the flame-cutting
machine.
• All flammable material should be removed from the cutting area (at a distance of 10 meters in
all directions).
• Let freshly cut metal cool before passing it on for further processing or before it comes in
contact with flammable materials.
• Never cut containers that hold flammable materials. These containers must be cleaned
thoroughly before cutting.
• Before using the machine, any areas that are likely to be flammable should be ventilated.
Never start the machine if there is a high concentration of flammable gas or combustible
vapors in the ambient air.

3.1.3 Preventing electrical shocks

The flame-cutting machine requires a power supply of 230 V AC / 50 Hz for the controller and
the motors. The user or operator of the flame-cutting machine must follow the following safety
rules.

• The body and clothing of operating personnel must be dry.

• The primary connection of the machine must be in conformance with the local safety
specifications.
• Examine the primary cable frequently for any damage to the insulation. Exposed wires are
very dangerous and can result in loss of life. Do not use the machine with a damaged
power cable. Immediately replace damaged cables.
• Examine the cables on the gantry bridge and replace them if they are worn or damaged.
• The controller unit and the switch cabinets should only be opened by qualified personnel, and
only such personnel should work inside them.
• Repair work on the entire machine should only be carried out with the power cut off. To do so,
switch off the main switch and if required, secure it with a locking device.
• Never bypass the safety interlocks on the machine, or render them inoperational.

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3.1.4 Preventing explosions

Warning!

This machine uses GAS under pressure. Suitable safety procedures must be followed for using
gas supplies. Refer to UVV VGB15.

Pay attention to the following when cutting with the machine:

• Do not operate the machine if the ambient air contains explosive dust or gases.
• Do not cut any gas cylinders that are under pressure.

3.1.5 Pressure reducer

• Keep all pressure reducers in an operationally safe condition. Damaged pressure reducers
can cause damage to the machine or injuries to persons; pressure reducers may only be
repaired and maintained by qualified personnel.
• Pressure reducers should only be used for the type of gas for which it has been design-
approved.
• Never use a pressure reducer that is leaky or damaged.
• Never let pressure reducers come in contact with oil or grease.

3.1.6 Gas supply from cylinders

• Follow the safety instructions in UVV VGB 15 when handling gas cylinders.
• Never use a gas cylinder that is leaky or damaged.
• Gas cylinders must always be stored in an upright position and secured against tipping over.
• Gas cylinders should only be moved or transported with the protective cover of the valve put
on.
• Gas cylinders and their contents should not be handled in an improper manner.
• Never let gas cylinder valves come in contact with oil or grease.
• There should be no electrical connection between the gas cylinder and the flame-cutting
machine.
• Protect the gas cylinders from excessive heat, sparks, slag or open flames.
• Never use a hammer, pliers or any other tool to open a gas valve that has got closed tight.

3.1.7 Gas tubes

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• Gases should only be carried in tubes or pipes that have been approved and tested for the
purpose.
• Limit the length of the tube to a minimum to prevent damage, to reduce the pressure-drop
and to avoid a possible constriction of the flow.
• Check tubes at regular intervals for leakage, wear, loose connections or other dangers.
• Replace tubes that have been damaged by wear, sparks, heat or open flames.
• Lay the tubes straight to avoid any kinks or folds.
• Roll up extra lengths of tubes and remove them from the walkways to avoid the danger of
damage and of stumbling.

3.1.8 Noise protection

The flame-cutting machines do not require any special noise protection in autogenous operation.
In case of additional equipment such as plasma oxygen cutting, plasma marking system or
powder-marking equipment, please take the necessary information from the relevant manuals or
operating instructions.

3.1.9 Safety devices

• The flame-cutting machines are equipped with emergency power-off switches and limit
switches that switch off the machine and bring it to a standstill as soon as they are actuated.
• The safety devices should never be bridged or made inoperational in any way.
• The flame-cutting machine may not be operated with the housing covers taken off; this poses
a danger of injury to the operating personnel and other persons in the working area.

3.1.10 Specifications and Guidelines

89/392/EWG,Annexure IIA, EC Guideline for machines

DIN EN 292, Safety of Machines, Equipment and Plants
DIN EN 60204.1, Electrical Equipment for Industrial Machines

Quality Standards (CE):

DIN 2310 Quality of cut
DIN 8523 Accuracy
VDE 0100/0113 Electrical Safety

4 Specifications

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4.1 Description

4.1.1 General

The Satronik flame-cutting machines of the D, HD, EHD, FB and DS series are distinguished by
a double gantry bridge with heat-protection plates and an integrated fan cooling system. The
have a double-sided longitudinal drive via a toothed rack and pinion. Both motors are
synchronized by means of a CNC controller. The C series has only one drive in the X-axis.
The flame cutting machine serves to cut various metals by autogenous or plasma arc cutting. It
is not intended for cutting flammable materials such as wood, paper etc.
The flame-cutting machines can be equipped with autogenous burners, plasma arc burners or
an endlessly rotatable three-burner assembly.

4.1.2 CNC track control

The CNC controller is constructed as an industrial computer in the ISA 96-BUS system. The
CNC application runs safely owing to its implementation as a real-time processing system. 8
analog inputs and 216 digital I/Os can be connected on the main boards. Additional cards are
available for axis connections. Up to 4 servo-axes can be operated with an analog interface. The
position or angle feedback is incremental. The CNC controller is programmed in the standard
ESSI format according to ISO 6582. Two serial interfaces and a floppy drive are provided for
reading the data.

4.1.3 Burner height adjustment

The burner height adjustment system E 2 xx mounted on a trolley with a covered roller guide,
pneumatic belt clamp, is a motorized burner lifter with max. XXX mm stroke. The burner height
adjustment system, as a unit, is maintenance-free.
The design, construction and number of burner height adjustment units are customized.

4.1.4 Standard autogenous equipment

The autogenous equipment is designed for flammable gases and is supplied via a central gas
distribution system for a maximum of 4 burner height adjusting systems. The central gas
distribution takes place via an electromagnetic central switch and has a ventilating valve for
the cutting oxygen. Remote regulation of the combustion gases is controlled by means of a
pressure-regulator and manometer unit.

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If desired, more burner height adjustment systems can be provided at an additional price.

Cutting thicknesses: Standard gas distribution

with 1 burner… max. 300 mm

with 2 burners… max. 200mm
with 3 burners… max. 150mm
with 4 burners… max. 100mm

4.1.5 Plasma Interlock Switch for one plasma flow source (optionally, several)

The plasma interlock switch is used for automatic starting of the plasma machine and its safety
monitoring. The plasma interlock switch automatically switches off the arc tracing when going
round corners. The various arc traces have an ignition high control for reaching the ignition
height on the sheet to be cut and re-adjust the height of the burner by means of a voltage
measurement on the arc.
The type of function "Ignition high control" can be found in the specification for the corresponding
arc tracer.

4.2 Technical data

4.2.1 Gantry bridge

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Track width : Nominal dimension

Working width max. : -600 mm of nominal width
Total width : Nominal dimension + 1000 mm
Feed : 10-12000 mm/min (optionally faster)
Connected rating : 230V/50Hz
Power drawn : 1.5 kVA

4.2.2 Continuous path control CNC 8xx

The continuous path control is located in a control panel (type S200-1-528-401-2) and (type
S200-1-529-401) with degree of protection IP 54.

The technical data:

CPU : 80486 DX 4, 32Bit/75MHz
Memory : 4 MB
Monitor : 10.4" LCD
Ports : 2x RS232C (V24)
Diskette drive : 3.5"; 1.44 MB (Standard)
Digital I/O-card : 48 inputs and 72 outputs, opto-decoupled and filtered
Position regulator : for 3 axes with 12 bit, potential-isolated, axis regulation time 5
ms

Continuous path control CNC 3xxx

The technical data

CPU : Pentium 2 300MHz
Memory : 64 MB RAM
Monitor : 15.1“ TFT
Ports : various
Diskette drive : 3.5"; 1.44 MB (Standard)
Digital I/O : CAN-LWL/BUS
Position regulation and SPS via a separate computer unit

5 Workplace

During the flame cutting process, the operating personnel should remain only outside the area
marked by the safety line. There is a danger of burning and injury on the flame-cutting table and
between the track and the flame-cutting table. Nobody should take up position behind the

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machine during the flame-cutting process either, because then it is not possible to observe the
movement path of the machine.

Caution !

There is a danger of injury and burning from cut parts. Let the cut parts cool and move them with
safety hand-gloves or, in the case of larger components, with the corresponding approved tools.

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5.1 Safety area

Fig. 3

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6 Installation

6.1 Pre-installation

The installation and maintenance of the electrical plant as well as of the piping must be in
conformance with the local rules related to electricity and installation. The work should only be
carried out by qualified and authorized personnel. In case of further questions, the technical
service department of SATO will be happy to assist you. TEL.: +49-2161-99420

6.1.1 On receiving the machine

Please unpack the machine when you receive it and check all the accompanying components
for damage and report immediately to the shipping agent and SATO if there is any. We would be
happy to forward a copy of the delivery note and the waybill.

6.1.2 Gas specifications

All the gases and piping that is required for the operation of the Satronik flame-cutting machines
should be provided by the customer. If the degree of purity of the gas is insufficient or the supply
pipes or joints have a leak:

• the cutting speed can get reduced

• the cutting quality can be adversely affected
• the ability to cut certain thicknesses can get reduced
• plant parts can get damaged
• there is a danger of explosion

6.1.2.1 Oxygen

The customer should provide a regulated oxygen supply that is able to deliver at a pressure of
15.0 bar at a purity of 99.95% and a throughput quantity of XXXXX l/min. The throughput
quantity is to be determined specifically for the customer. The oxygen supply should be
connected to the central gas distribution system.

6.1.2.2 Fuel gas

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Warning!

Gas is flammable and dangerous. There is a danger of explosion. Gas cylinders and gas tubes
should be kept away from open flames.

The customer should provide a gas supply, normal commercial quality, with a feed pressure of
0.7 bar at the burner output at a throughput quantity of xxx l/min per burner. The gas supply
should be connected to the central gas distribution system.

6.1.2.3 Air

The air must be clean, dry and free of oil at a pressure of 6-8 bar. The air should be connected
to the joint of the main supply on the bridge.

6.1.3 Electrical power requirements

The power cable is shipped accompanying the machine. A 3-core 2.5mm2 power supply cable
with a conductor temperature range of 60°C should be used.

6.1.4 Potential equalization

The machine requires a high-quality grounding that is in conformance with the national and local
electrical rules. The guarantee becomes null and void if the machine is not connected properly.

6.1.5 Connecting the power cable

L1, N and PE are color-coded on the main switch of the machine and must be connected by
matching the colors. The machine requires, without fail, a power connection that is isolated from
the plasma current source with 230V AC/16A/50-60 Hz. The power supply connection is subject
to the national and local electricity regulations.
The guarantee becomes null and void if the machine is not connected properly.

6.2 Installation

6.2.1 Erection of the machine and its components

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The flame-cutting machines of type SATRONIK  should be installed according to the European
Norm EN 28206. The European Norm EN 28 206: 1992 has the status of a German standard. It
is identical to ISO 8206 : 1991 and contains the text of DIN 8523/05.74, with contents
unchanged.

6.2.1.1 Foundation (to be readied by the customer)

(drawing in the annex)

6.2.1.2 Connecting tubes and cables

Except for the main supply (gas tubes, compressed air pipes, grounding cable, power supply
cable and the plasma tube packet), the machine is connected. Feed these cables and pipes in
parallel through the energy chain and connect them in a technically proper manner.
The central gas distribution, the main switch, the potential-equalizing busbar and the
compressed air connection are located on the gantry bridge as in the following graphic.
The main switch must be so wired that L1 and N are switched off.

Caution !

Danger: Electric supply

Switch off all power to the machine before starting work!!

Compressed air pipe, main switch central gas distribution

Druckluftschlauch
Gasezentralverteilung
Hauptschalter

Potentialausgleichsschine

Bedienpult

Operating console, Equipotential busbar

The central gas distribution system should be connected according to the graphic above.
Thereafter, the pipes should be checked for leakage. Please seal the threaded joints in a
technically proper manner.

Take care!

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Never lubricate threaded joints with oil or grease. Never glue the threaded joints with normal
adhesive. Please use an adhesive that has been specially developed for oxygen or fuel gas. If
you are not able to locate a suitable adhesive, please check with your gas supplier or with
SATO.

Connect the grounding cable in a technically proper manner to the equipotential busbar. Only
use materials that conform to your national or local electricity rules for this purpose.

Take care!

The grounding is very important for fault-free operation. Especially when using a plasma plant or
during welding work on the flame-cutting table, sensitive faults can jeopardize the flame-cutting
operation. Protect the electronics from over-voltage and high frequency.
How the burning tables are to be grounded is given in the manual of your plasma cutting device.
Basic rule when grounding:
Always ground in star formation for potential equalizing. Avoid closed ring conductors.

6.3 The correct foundation

The foundation must be built according to the national and local guidelines. For this purpose,
please contact an authorized construction contractor. Further information can be obtained
from your local building authority.

The installation of the I-beams (HE-300B) can be seen in the drawing (foundation plan).

6.4 After installation

6.4.1 Starting the machine

When all the work has been carried out properly, you can switch the machine on. The functions
of the controller have been explained in detail in the chapter Controls.

6.4.2 General function test

Now, carry out the general function test according to the European Norm EN 28 206, page 6-10.
Changes in the configuration that the function test indicates have to be made can be carried out
in the configuration file (chapter 12). In this context, please carefully read chapter 12. Should
you have problems in configuring the machine, please contact the Service Department of SATO
(Tel.: +49-2161-99420)

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